09103-06180 Suzuki BOLT

1. Install Tool (A) as shown. 2. Install Tool (B) in the fuel pump housing as shown with the square end down. Use a small amount of hand force to push down on Tool (B) while the fuel control lever is moved forward to the "FUEL ON" position. Rack travel will stop in the center (zero) position. Hold a light forward force on the governor control lever to keep the fuel racks in the center (zero position). 3. Use Tool (A) to turn the engine in a counterclockwise direction (as seen from the flywheel end of the engine) until timing bolt (2) can be installed into the flywheel. The No. 1 piston must be at top center on the compression stroke. If the hole in the flywheel is turned beyond the hole in the flywheel housing, turn the flywheel back (clockwise) a minimum of 30 degrees beyond the hole in the flywheel before turning counterclockwise toward the hole again. This will prevent a timing error caused by play in the timing gears.4. To see if No. 1 piston is on the compression stroke, look at the valves of No. 1 cylinder. The valves will be closed if No. 1 cylinder is on the compression stroke. You should be able to move the rocker arms up and down with your hand.If No. 1 piston is not on the compression stroke, turn the flywheel 360 degrees, and install the timing bolt.5. Remove fuel ratio control (1).6. Remove governor control cylinder (2).7. Remove fuel transfer pump (3). 8. Remove fuel injection lines (4).9. Remove two brackets (6) that are bolted to the cylinder heads and the fuel injection pump housing.10. Remove tubes (5) from each side for better access to bolts (7).11. Remove two bolts (7) from each side of the fuel injection pump housing.12. Be sure all disconnections have been made for governor removal.13. Pull the fuel injection pump out of the timing gear housing.14. Fasten a nylon strap and hoist to the fuel injection pump housing and governor. The weight of the fuel injection pump housing and governor is 59 kg (130 lb).
Do not damage the oil inlet and oil outlet dowels on the bottom of the fuel injection pump housing.
15. Inspect the O-ring seals on the bottom of the fuel injection pump housing. Inspect the O-ring seal on the front of the fuel injection pump housing. Replace the O-ring seals if necessary.Install Fuel Injection Pump Housing & Governor
1. Remove timing bolt (1), cover (2) and plug (3). 2. Use Tool (A) to turn the engine in a counterclockwise direction (as seen from the flywheel end of the engine) until timing bolt (1) can be installed into the flywheel. When the timing bolt can be turned freely in the threaded hole in the flywheel, the No. 1 piston is on top center. If the hole in the flywheel is turned beyond the hole in the flywheel housing, turn the flywheel back (clockwise) a minimum of 30 degrees beyond the hole in the flywheel before turning counterclockwise toward the hole again. This will prevent a timing error caused to play in the timing gears. 3. To see if No. 1 piston is on the compression stroke, look at the valves of No. 1 cylinder. The valves will be closed if No. 1 cylinder is on the compression stroke. You should be able to move the rocker arms up and down with your hand.4. If No. 1 piston is not on the compression stroke, turn the flywheel 360 degrees, and install the timing bolt. 5. Remove the plug from the front of the governor plate. Install Tool (B) through the hole in the plate and turn the fuel pump camshaft until Tool (B) can be installed into the notch.
Make sure there is no paint, dirt or foreign material on the machined surface of the fuel injection pump housing and the machined surface of the cylinder block. The surface must be clean before the fuel injection pump housing is installed.
6. Inspect the two O-ring seals on the bottom of the fuel injection pump housing for wear or damage, and replace if necessary. Put 5P-960 Multi-Purpose Type Grease on the O-ring seals to hold them in place on the bottom of the fuel injection housing over the oil inlet and outlet dowels.7. Inspect the O-ring seal on the front of the fuel injection pump for wear or damage, and replace it if necessary. Put clean engine oil on the seal.8. Fasten a nylon strap and hoist to the fuel injection pump housing and governor, and put it in position on the engine.9. Install the bolts and the brackets that hold the fuel injection pump housing to the engine.10. Install the cooling system tubes removed for access to the fuel injection pump housing bolts.11. Install the fuel injection lines.12. Install the fuel transfer pump.13. Install the governor control cylinder.14. Install fuel ratio control. Adjust the fuel settings (see Fuel System Adjustments On Engine in Engine Testing & Adjusting).